ES2961556A1 - Métodos de manufactura de bordes de rigidizadores a neto - Google Patents
Métodos de manufactura de bordes de rigidizadores a neto Download PDFInfo
- Publication number
- ES2961556A1 ES2961556A1 ES202230738A ES202230738A ES2961556A1 ES 2961556 A1 ES2961556 A1 ES 2961556A1 ES 202230738 A ES202230738 A ES 202230738A ES 202230738 A ES202230738 A ES 202230738A ES 2961556 A1 ES2961556 A1 ES 2961556A1
- Authority
- ES
- Spain
- Prior art keywords
- edge
- web
- section
- stiffener
- cross
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 239000003351 stiffener Substances 0.000 title claims abstract description 47
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 31
- 238000000034 method Methods 0.000 title abstract description 10
- 239000002131 composite material Substances 0.000 claims abstract description 36
- 239000011152 fibreglass Substances 0.000 claims abstract description 17
- 239000004918 carbon fiber reinforced polymer Substances 0.000 claims abstract description 11
- 238000000465 moulding Methods 0.000 claims description 17
- 229920000049 Carbon (fiber) Polymers 0.000 abstract description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 abstract description 2
- 238000007688 edging Methods 0.000 description 7
- 230000000694 effects Effects 0.000 description 7
- 239000011347 resin Substances 0.000 description 4
- 229920005989 resin Polymers 0.000 description 4
- 230000032798 delamination Effects 0.000 description 3
- 239000000835 fiber Substances 0.000 description 3
- 238000007789 sealing Methods 0.000 description 3
- 238000007493 shaping process Methods 0.000 description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical group [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 239000003082 abrasive agent Substances 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 230000000295 complement effect Effects 0.000 description 1
- 238000007596 consolidation process Methods 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 239000003925 fat Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000003801 milling Methods 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
Classifications
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- B29C53/34—Rim rolling
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- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
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Abstract
Métodos de manufactura de bordes de rigidizadores a neto. Método de manufactura de un rigidizador de material compuesto polimérico reforzado con fibra de carbono, CFRP, con una sección trasversal en "T", donde el rigidizador se obtiene de una preforma (100) que comprende un alma (120) y un pie (130), donde el pie (130) corresponde a un borde del rigidizador configurado para estar en contacto con un panel de una aeronave, y donde el alma (120) corresponde a la parte restante del rigidizador y la cual comprende un borde del alma (120a), el método de manufactura comprende las siguientes etapas obtener dos laminados (110a, 110b) que comprenden un conjunto de capas de material compuesto, conformar los dos laminados (110a, 110b) mediante el doblado de los dos laminados (110a, 110b) en sección trasversal en "L", unirlos dos laminados (110a, 110b) para obtener la preforma (100) con una sección trasversal en "T", moldear el borde del alma (120a) para obtener una sección trasversal semicircular, aplicar al borde del alma (120a) una tira de tejido de carbono semicurado (L1), una tira húmeda de fibra de vidrio preimpregnado (L2)en fresco y curar la preforma (100) para obtener el rigidizador con una sección trasversal en "T" con el borde del alma (120a) a neto.
Description
DESCRIPCIÓN
Métodos de manufactura de bordes de rigidizadores a neto
Objeto de la invención
El objeto de la presente invención se refiere a métodos de manufactura de rigidizadores de material compuesto polimérico reforzado con fibra de carbono, en particular, a métodos para la obtención de la forma "a neto” de un borde de los rigidizadores que permite eliminar las operaciones de recanteado y de sellado.
Antecedentes de la invención
El proceso estándar para conseguir la fabricación ‘a neto’ de un borde de los rigidizadores o larguerillos con una sección trasversal en “T” con un "alma” y un "pie” (donde el pie corresponde a un borde del rigidizador configurado para estar en contacto con un panel de una aeronave, y donde el alma corresponde a la parte restante del rigidizador) es la de recortar el exceso de material sobrante mediante un proceso llamado recanteado (i.e. se corta el material sobrante del borde con fresa o disco aplicando chorro de agua). El proceso de recanteado se lleva a cabo después del curado de la preforma sobre el que se obtiene el rigidizador con una sección trasversal en “T”. El recanteado se realiza con equipos especializados, los cuales consumen tiempo, así como materiales duros y abrasivos.
La necesidad de recantear el borde del rigidizador después del curado se debe a la mala calidad obtenida en los bordes de la preforma de laminado de material compuesto. Si el borde se moldea usando útiles de conformado (por ejemplo, conformado mediante rodillos), es altamente complicado hacer coincidir el borde del laminado ya conformado con la cavidad del útil de curado. Por lo tanto, se genera un espacio entre el borde del laminado ya conformado y la cavidad del útil de curado. Este espacio se llena con resina y fibras, lo que reduce las propiedades del laminado.
Desventajosamente:
La operación de recanteado puede generar delaminaciones en el borde de la preforma sometida a recanteado y la operación de conformado de los laminados de material compuesto puede crear el denominado efecto libro. En particular:
La figura 1 muestra una preforma (100) de un rigidizador con sección transversal en "T”. La preforma (100) comprende un alma (120) y un pie (130) (donde el pie (130) corresponde al borde del rigidizador configurado para estar en contacto con un panel de una aeronave). Cuando la preforma (100) se ha conformado mediante el doblado de dos laminados de material compuesto (110a, 110b) con una sección transversal en "L” por el "alma” (120) del rigidizador, las diferentes longitudes de cada capa de los laminados de material compuesto (110a, 110b) que siguen al radio (R) crean lo que se denomina efecto libro en el borde del alma (120a), donde las capas internas (C) de los laminados de material compuesto (110a, 110b) son más cortas que las externas.
Por último, cuando las piezas (por ejemplo, las costillas del ala de la aeronave) de metal (por ejemplo, de aluminio o titanio) están cerca del borde del rigidizador recanteado, se requiere de una operación adicional de sellado para cubrir los filamentos de carbono y evitar la corrosión en el metal.
La presente invención solventa las desventajas remanentes en el estado de la técnica a la hora de la fabricación "a neto” del borde del alma de un rigidizador con una sección transversal en "T”.
Descripción de la invención
La presente invención se refiere a un método de manufactura que permite la fabricación ‘a neto’ de un borde del alma de los rigidizadores o larguerillos con sección trasversal en "T” y que evita los procedimientos de recanteado y de sellado existentes en el estado de la técnica, aislando los filamentos de carbono del borde del alma del rigidizador.
Así pues, en un primer aspecto, la presente invención se refiere a un método de manufactura de un rigidizador de material compuesto polimérico reforzado con fibra de carbono, CFRP, con una sección trasversal en "T”, donde el rigidizador se obtiene de una preforma que comprende un alma y un pie, donde el pie corresponde a un borde del rigidizador configurado para estar en contacto con un panel de una aeronave, y donde el alma corresponde a la parte restante del rigidizador y la cual comprende un borde del alma.
El método de manufactura comprende la etapa de obtener dos laminados que comprenden un conjunto de capas de material compuesto, y la etapa de conformar cada uno de los dos laminados de material compuesto mediante el doblado de los laminados de material compuesto, cada laminado con una sección trasversal en "L” ;
El método de manufactura comprende la etapa de unir los dos laminados para obtener la preforma con una sección trasversal en "T”. En particular, con dos laminados cada uno con sección trasversal en "L” , se pueden unir con un alma de la "L” de un primer laminado, a espalda de un alma de la "L” del segundo laminado, con los bordes del alma a misma altura, de tal forma a obtener la preforma con una sección trasversal en "T”.
El método de manufactura comprende la etapa de moldear el borde del alma para obtener una sección trasversal del borde del alma semicircular. El borde libre del alma de la preforma es así redondeado, de tal forma que es menos propenso a delaminación o al almacenar líquidos como agua, grasas, etc. que con tiempo, podrían deteriorar el laminado.
El método de manufactura comprende la etapa de aplicar al borde del alma una tira de fibra de vidrio semicurado y una tira de fibra de vidrio preimpregnado en fresco Las tiras de fibra aplicadas al borde moldeado del alma, permiten mantener juntos los bordes de los laminados, y así asegurar que el borde del alma mantendrá su forma redondeada en el tiempo, así como evitar aún más la delaminación del borde del alma. Con tiras, el borde del alma queda con un acabado continuo liso, o "a neto”.
Finalmente, el método de manufactura comprende la etapa de curar la preforma para obtener el rigidizador con una sección trasversal en "T” con el borde del alma a neto. Una vez curada, la forma del borde del alma, y las tiras que lo cubren se mantienen en su posición y su forma se mantiene sin modificación.
En un primer ejemplo, el método de manufactura comprende la etapa de aplicar a la preforma una bolsa de vacío flexible previamente al curado, la cual se retira del rigidizador después de la etapa de curado.
En un primer ejemplo, el método de manufactura comprende la etapa de aplicar calor al borde del alma para ablandar el conjunto de capas de material compuesto. El calor aplicado es suficientemente bajo para que no se cure la resina del CFRP.
En un primer ejemplo, el método de manufactura además comprende moldear el borde del alma para obtener una sección trasversal con forma de cuña previa a la sección trasversal semicircular. Moldear el borde del alma para obtener una sección trasversal con forma de cuña permite pasar más fácilmente de una forma abierta de borde del alma en "V” cuando los dos laminados están unidos el uno con el otro "a espaldas”, a una forma semicircular.
Otro aspecto de la invención se refiere a un rigidizador que comprende una geometría específica con una sección transversal en "T” obtenido mediante el método de manufactura de acuerdo con el primer aspecto de la invención.
Un tercer aspecto de la invención se refiere a un dispositivo para el moldeado de un borde de un alma de una preforma de un rigidizador de material compuesto polimérico reforzado con fibra de carbono, CFRP, con una sección trasversal en "T”, donde el rigidizador comprende un alma y un pie, donde el pie corresponde a un borde del rigidizador configurado para estar en contacto con un panel de una aeronave, y donde el alma corresponde a la parte restante del rigidizador.
El dispositivo comprende un dispositivo de aplicación de calor configurado para ablandar el conjunto de capas de material compuesto del borde del alma de la preforma y un conjunto de rodillos configurados para obtener el borde del alma con una sección trasversal semicircular.
El conjunto de rodillos comprende un primer grupo de rodillos en cuña para moldear el borde del alma con una sección trasversal en cuña.
El conjunto de rodillos comprende un segundo grupo de rodillos de redondeado con forma de medialuna para moldear el borde del alma con una sección trasversal semicircular.
Descripción de los dibujos
Para complementar la descripción que se está realizando y con objeto de ayudar a una mejor comprensión de las características de los métodos de manufactura de acuerdo con la presente invención, se acompaña como parte integrante de dicha descripción, un juego de dibujos en donde con carácter ilustrativo y no limitativo, se ha representado lo siguiente:
La figura 1 muestra una preforma de un rigidizador con una sección transversal en "T” y el efecto libro generado en el borde del alma del rigidizador.
La figura 2 muestra el conformado mediante moldeo del borde del alma de la preforma.
Las figuras 3A y 3B muestran las etapas de moldeado del proceso de manufactura de acuerdo con la presente invención.
La figura 3C muestra la etapa de aplicación al borde del alma de una tira de fibra de vidrio semicurado, una tira de fibra de vidrio preimpregnado, así como la aplicación a la preforma de una bolsa de vacío flexible.
Realización detallada de la invención
La figura 1 muestra la preforma (100) ( "en fresco” o "pre-curada”) obtenida tras las etapas del método de manufactura de acuerdo con la presente invención correspondientes a obtener dos laminados de material compuesto (110a, 110b) que comprenden un conjunto de capas de material compuesto, conformar cada uno de los dos laminados de material compuesto (110a, 110b) mediante el doblado de los laminados de material compuesto (110a, 110b) cada uno con una sección trasversal en "L” y unir los dos laminados de material compuesto (110a, 110b) para obtener la preforma (100) con una sección trasversal en "T”.
Como se aprecia en la figura 1, las diferentes longitudes de cada capa de los laminados de material compuesto (110a, 110b) crean un borde del alma (120a) en forma abierta en "V”.
La figura 2 muestra la etapa de moldear (o etapa de moldeado) el borde del alma (120a) de la preforma (100) que elimina el efecto libro:
El moldeado se lleva a cabo posteriormente a la etapa de obtener dos laminados de material compuesto (110a, 110b) que comprenden un conjunto de capas de material compuesto, como se muestra en la preformar (100) de la figura 1.
El moldeado también se lleva a cabo posteriormente a la etapa de conformar los dos laminados de material compuesto (110a, 110b) mediante el doblado de los dos laminados de material compuesto (110a, 110b) en sección trasversal en "L” , y a la etapa de unir los dos laminados de material compuesto (110a, 110b) con una sección trasversal en "T” para obtener la preforma (100) del rigidizador.
Al doblar los dos laminados de material compuesto (110a, 110b) se genera un efecto libro en el borde del alma (120a), el cual se aprecia en la figura 1 del estado de la técnica resultando en un borde del alma en "V”, y se describe en el apartado antecedentes de la invención de la presente descripción. Para eliminar el efecto libro del borde del alma (120a), el proceso de manufactura de acuerdo con la presente invención comprende la etapa de moldeado del borde del alma (120a) de la preforma (100), el cual se muestra en la figura 2, una vez obtenida la sección trasversal en "T”.
Como se muestra en la figura 2, la etapa u operación de moldeado se lleva a cabo con el dispositivo (1000) configurado para, mediante un dispositivo de aplicación de calor (300), en una primera fase, aplicar calor al borde del alma (120a) para ablandar el conjunto de capas de material compuesto de dicho borde, y en una segunda fase, mediante un conjunto de rodillos en cuña (310) y un conjunto de rodillos de redondeado (311), moldear la superficie del borde del alma (120a) para obtener el borde del alma (120a) con una sección trasversal semicircular. Al final de esta etapa se crea una forma redondeada en borde del alma (120a), cerrando el espacio interno asociado a las capas interiores más cortas y eliminando así el efecto libro.
La figura 3A muestra la etapa de moldeo de la superficie del borde del alma (120a) mediante un grupo de rodillos en cuña (310) los cuales comprenden una forma de cuña para moldear el borde del alma (120a) con una sección en cuña.
La figura 3B muestra la etapa de moldeo de la superficie del borde del alma (120a) mediante un grupo de rodillos de redondeado (311) con forma de medialuna para moldear el borde del alma (120a) con una forma final que comprende una sección trasversal semicircular.
La figura 3C muestra la etapa de aplicar al borde del alma (120a) una tira de fibra de vidrio semicurado (L1), una tira de fibra de vidrio preimpregnado (L2) en fresco, así como la aplicación a la preforma de una bolsa de vacío flexible (L3), previamente a la etapa de curado, consiguiendo así un borde del alma (120a) "a neto”.
El borde del alma (120a) se cubre con un perfil de fibra de vidrio semicurado (L1), y por encima una tira de fibra de vidrio preimpregnado (L2) en fresco. El estado del perfil de fibra de vidrio (L1) proporciona la suficiente rigidez para moldear el borde del alma (120a) de forma controlada y permite conseguir una buena adhesión con la resina de la preforma (100). El estado fresco de la tira preimpregnada de fibra de vidrio (L2) permite fijar el perfil de fibra de vidrio semicurado (L1) en el borde del alma (120a) una vez curada la preforma (100).
La preforma (100) junto con el perfil de fibra de vidrio que comprende la tira de fibra de vidrio semicurado (L1) y la tira de fibra de vidrio preimpregnado (L2) en fresco se curan envueltos en la bolsa de vacío flexible (L3) que se adapta a la forma real del borde del alma (120a) como se aprecia en la figura 3C, consiguiendo una buena consolidación sin movimientos de resina ni de fibra, obteniendo así un borde del alma (120a) "a neto”. Dicha bolsa de vacío flexible (L3) se puede retirar del rigidizador después de la etapa de curado.
Claims (8)
1. Método de manufactura de un rigidizador de material compuesto polimérico reforzado con fibra de carbono, CFRP, con una sección trasversal en "T”, donde el rigidizador se obtiene de una preforma (100) que comprende un alma (120) y un pie (130), donde el pie (130) corresponde a un borde del rigidizador configurado para estar en contacto con un panel de una aeronave, y donde el alma (120) corresponde a la parte restante del rigidizador y la cual comprende un borde del alma (120a), el método de manufactura comprende las siguientes etapas:
- obtener dos laminados de material compuesto (110a, 110b) que comprenden un conjunto de capas de material compuesto;
- conformar cada uno de los dos laminados de material compuesto (110a, 110b) mediante el doblado de los laminados de material compuesto (110a, 110b) cada uno con una sección trasversal en "L”;
- unir los dos laminados de material compuesto (110a, 110b) para obtener la preforma (100) con una sección trasversal en "T”;
- moldear el borde del alma (120a) para obtener una sección trasversal del borde del alma (120a) semicircular;
- aplicar al borde del alma (120a) una tira de fibra de vidrio semicurado (L1) y una tira de fibra de vidrio preimpregnado (L2) en fresco y
- curar la preforma (100) para obtener el rigidizador con una sección trasversal en "T” con el borde del alma (120a) a neto.
2. Método de manufactura de acuerdo con la reivindicación 1, que además comprende aplicar calor al borde del alma (120a) para ablandar el conjunto de capas de material compuesto.
3. Método de manufactura de acuerdo con las reivindicaciones 1 o 2, que además comprende:
- aplicar a la preforma una bolsa de vacío flexible (L3) previamente a la etapa de curar la preforma (100); y
retirar la bolsa de vacío flexible (L3) después de dicha etapa.
4. Método de manufactura de acuerdo con las reivindicaciones anteriores, , que además comprende moldear el borde del alma (120a) para obtener una sección trasversal en cuña previa a la sección trasversal semicircular.
5. Rigidizador que comprende una geometría específica con una sección transversal en "T” obtenido mediante el método de manufactura de acuerdo con las reivindicaciones 1 a 4.
6. Dispositivo (1000) para el moldeado de un borde de un alma (120a) de una preforma (100) de un rigidizador de material compuesto polimérico reforzado con fibra de carbono, CFRP, con una sección trasversal en "T”, donde el rigidizador comprende un alma (120) y un pie (130), donde el pie (130) corresponde a un borde del rigidizador configurado para estar en contacto con un panel de una aeronave, y donde el alma (120) corresponde a la parte restante del rigidizador, el dispositivo (1000) comprende: - un dispositivo de aplicación de calor (300) configurado para ablandar el borde del alma (120a) de la preforma (100); y
- un conjunto de rodillos configurados para moldear el borde del alma (120a) para obtener una sección trasversal semicircular.
7. El dispositivo (1000) de acuerdo con la reivindicación 6, donde el conjunto de rodillos comprende un grupo de rodillos en cuña (310) configurados para moldear el borde del alma (120a) para obtener una sección trasversal en cuña.
8. El dispositivo (1000) de acuerdo con la reivindicación 7, donde el conjunto de rodillos comprende un grupo de rodillos de redondeado (311) configurados para moldear el borde del alma (120a) con forma de medialuna para obtener la sección trasversal semicircular.
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ES202230738A ES2961556A1 (es) | 2022-08-09 | 2022-08-09 | Métodos de manufactura de bordes de rigidizadores a neto |
EP23382783.1A EP4321329A2 (en) | 2022-08-09 | 2023-07-27 | Manufacturing methods of net stiffeners |
CN202310969429.0A CN117584496A (zh) | 2022-08-09 | 2023-08-03 | 网状加强筋的制造方法 |
US18/365,803 US20240051244A1 (en) | 2022-08-09 | 2023-08-04 | Manufacturing methods of net stiffeners |
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US20080087768A1 (en) * | 2006-06-14 | 2008-04-17 | Airbus Uk Limited | Aircraft component |
US20110220006A1 (en) * | 2007-08-08 | 2011-09-15 | Airbus Uk Limited | Composite laminate structure |
US9676147B2 (en) * | 2012-06-29 | 2017-06-13 | Airbus Operations S.L. | Method of manufacturing T-shaped stringer with a rounded web end |
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WO2010083840A2 (en) * | 2009-01-21 | 2010-07-29 | Vestas Wind Systems A/S | Method of manufacturing a wind turbine blade by embedding a layer of pre-cured fibre reinforced resin |
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US20080087768A1 (en) * | 2006-06-14 | 2008-04-17 | Airbus Uk Limited | Aircraft component |
US20110220006A1 (en) * | 2007-08-08 | 2011-09-15 | Airbus Uk Limited | Composite laminate structure |
US9676147B2 (en) * | 2012-06-29 | 2017-06-13 | Airbus Operations S.L. | Method of manufacturing T-shaped stringer with a rounded web end |
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